Nanoparticle enhanced poly(lactic acid) melt-blown for efficient and eco-friendly oil spill cleanup

Crude oil spills remain a persistent environmental challenge, creating long-term ecological and economic damage, highlighting the need for efficient, biodegradable absorbent materials. Conventional polypropylene (PP) sorbents are widely used for spill cleanup but generate secondary environmental concerns because of their non-biodegradable nature. Poly(lactic acid) (PLA), a renewable and biodegradable thermoplastic, offers a sustainable alternative; however, its inherent oil sorption capacity is limited. In this study, PLA melt-blown nonwoven sorbents were enhanced using calcium carbonate nanoparticles (CCN) to improve porous structure, wettability, and oil uptake performance. PLA/CCN composites containing 3–10 phr CCN were fabricated through a scalable melt-blown process. Low CCN concentrations (3–5 phr) enabled uniform nanoparticle dispersion and the development of mesoporous structures (average pore width ∼3.8 nm), resulting in increased surface area and improved oil uptake. The PLA/CCN composite containing 10 phr CCN exhibited the highest absorption capacity (16 g/g), surpassing commercial PP sorbents in oil uptake capacity. However, excessive filler loading also promoted particle agglomeration and reduced structural uniformity. Mechanical testing showed that moderate nanoparticle loading improved stiffness, whereas higher loading decreased ductility. Thermal analyses confirmed increased crystallinity and enhanced stability with CCN addition. Adsorption behavior followed the Freundlich isotherm (R ² = 0.98), indicating a heterogeneous, multilayer sorption mechanism, whereas overall oil uptake is governed primarily by capillary retention within the fibrous network, with secondary surface adsorption contributions. Overall, PLA/CCN composites demonstrate strong potential as sustainable, high-performance sorbents for oil spill remediation and provide a viable pathway for designing advanced biodegradable nanocomposites for environmental applications.